Packaging apparatus



May 22, 1962 J. H. LEMELSON 3,035,382

' PACKAGING APPARATUS Filed Aug. 5, 1959 3 Sheets-Sheet 1 INVENTOR. Jerome H.Leme lson y 1962 J. H. LEMELSON 3,035,382

PACKAGING APPARATUS Filed Aug. 5, 1959 3 Sheets-Sheet 2 v v INVENTOR. Jerome H Lemels May 22, 1962 J. H. LEMELSON PACKAGING APPARATUS 3 Sheets-Sheet 3 Filed Aug. 5, 1959 A Q Q 7 41/44 1 D 5 INVENTOR. Jerome H.Lemelson United States Patent Gt ice 3,035,382 PACKAGING APPARATUS Jerome H. Lemelson, 8B Garfield Apts., Metuchen, NJ. Filed Aug. 5, 1959, Ser. No. 831,893 12 Claims. (Cl. 53-134) This invention relates to packaging machinery and is a continuation in part of my copending application entitled Welding Techniques, Serial No. 519,014, filed on June 29, 1955. In particular, this invention refers to apparatus for forming packaging structures described in my copending patent application, Serial No. 831,196, for Packaging Assembly, filed on August 3, 1959. Specifically, this invention relates to apparatus for forming and securing one or more containers or closures to part of a package or an insert for said package.

It is a primary object of this invention to provide new and improved automatic packaging apparatus.

Another object is to provide new and improved automatic sheet forming apparatus which may be used in the fabrication of improved types of packaging on an automatic basis without the need for human handling.

Another object is to provide improved package forming apparatus which includes means for automatically filling or partially filling containers or the like formed by said apparatus.

Another object is to provide automatic machinery for continuously forming sub-packages or small containers which are generally packaged in a master carton or larger containers, said apparatus including means for welding or bonding the containers to a base sheet or a wall of the master carton and the means for automatically filling or partially filling said sub-containers.

Another object is to provide improved package forming and filling apparatus which may be made to operate continuously without interruption for the manufacture of packages containing a plurality of smaller containers or sub-packages which contain different materials which may be filled with said different materials by said apparatus on an automatic basis without the need for human han dling of said materials.

Another object is to provide new and improved package forming and filling apparatus which may be programmed to effect the shaping and pre-positioning of different sub-containers in different arrays in a master carton without the need for major adjustments to said apparatus.

Another object is to provide a new and improved machine for automatically forming a plurality of small containers of the same or different shapes and for securing said container in predetermined positions on a base sheet or carton insert which serves as a conveyor thereafter for said containers and as a means for pre-positioning said containers relative to automatic filling apparatus, said apparatus including means for automatically loading one or more of said inserts with containers secured thereon into a box or master carton.

The invention also consists of certain new and original features of construction and combination of parts hereafter set forth as claimed.

The nature of the invention, as to its objects and advantages, the mode of its operation and the manner of its organization, may be better understood by referring to the following description taken in connection with the accompanying drawings forming a part thereof in which:

FIG. 1 is a fragmentary view in sectioned end-elevation of aligned heat'forming dies comprising part of the invention;

FIG. 2 shows the sheet forming dies of FIG. 1 brought together;

FIG. 3 illustrates the sheet forming dies brought apart 3,635,382 Patented May 22, 1962 with the component formed thereby retained by one of said dies;

FIG. 4 is a sectioned view of one of the dies of FIG. 3 in the act of welding the part formed thereon to another sheet;

FIG. 5 is a fragmentary view of the product formed by the apparatus of FIGS. 1 to 4;

FIG. 6 is an end-elevation of a fragmentary detail of an alternate design for the die of FIG. 4;

FIG. 7 is an end-elevation of a further die design replacing one of the dies of FIG. 4;

FIG. 8 is an isometric view of an automatic packaging machine utilizing components of FIGS. 1 to 7;

FIG. 9 illustrates control apparatus for the packaging apparatus shown in FIG. 8.

FIGS. 1 to 3 illustrate in cross-section, portions of a male and female die which coact to form a packaging member in the form of an open cup from a sheet material such as plastic, metal foil or the like and FIG. 4 shows a section of the same male die coacting with another die for welding the container shaped thereby to a second sheet material. Thus, at least part of the die assembly used to shape the container is also used to weld it to a second material. Part of the resulting article of manufac ture is shown in FIG. 5 which consists of a cup shaped container 20 which is welded at 23 to a base sheet 24, which weld 23 serves not only to hold said cup shaped container in a predetermined position on said base sheet but will also prevent its movement or shifting during transit. The base may also serve as a shock absorbing means for both the container and its contents. References made to my copending. application Serial #831,196 in which are shown various designs for packaging containers and means for securing the base or a wall of said containers to either a package divider, bottom or insert. The apparatus of this invention may be utilized for rapid and economical fabrication of such packaging and for automatically filling the attached containers with a product to be dispensed thereby.

In FIG. 1 a thin sheet 19 of deformable material is provided on the surface of a base platen or female die 17 and is preferably held thereon by means of rollers or clamps (not shown). A male die 10, part of which is illustrated, having a tapered nose 12 which is C011. toured for fitting engagement into a cavity 18 in the female die 17 and is adapted to shape the sheet 19 therein when 10 is advanced with sheet 12 directly over said cavity, preferably contains a row or a plurality of rows of tapered protruding portions such as 12 which may be frusto-conical in shape for forming such cups of the shape illustrated in FIG. 5. The external surface of 12 and the wall 13' of the cavity 18 may also be shaped to provide corrugations in the wall of the container 20 formed there-between for stiffening said walls. The nose 12 and cavity 18 may be formed into any suitable shape and may be rectangular or semi-spherical. If the sheet 19 is made of a metal such as aluminum or aluminum foil, it may be easily deformed into the cavity 18 when the nose 12 advances as in FIG. 2, provided that it is not completely restrained. The sheet 19 may also be made of a plastic material or a lamination of plastic and metal foil. If the material 19 is a thermo-plastic or lamination or a thermo-plastic and foil, it may be formed into the shape illustrated in FIG. 5 by the application of heat either to the female die 19 on which it rests or by means of a radiant heater applied above the die just before 10 advances over cavity 18. In FIG. 3, the die 10 is shown retracted from 17 so that its end clears the upper sur face of the female die. The cup 20 is shown held against the surface of the nose 12 and is carried therewith over a bucking member or third die 25 such asillustrated in FIG. 4. The two dies 19 and 25 coact thereafter to effect a spot weld 26 between the bottom 22 of 20 and the sheet 24. The notation 17 refers to a hole through the female die 17 extending through the bottom wall of the cavity 18 to which suction pressure may be applied, which pressure may be utilized to perform either or both of two functions. The vacuum pressure applied through 17' may be utilized to hold the sheet 19 against the upper surface of die 17 and/or to assist in the formation of the cup. For example, if the sheet 19 is made of a thermo-plastic material which is in a semi-molten condition prior to the advancement of 10, the plastic over the opening in 18 will be drawn into the die, which action may be completed or partially effected before the die nose 12 advances into said cavity. The die nose 12 may therefore either be used to effect the complete formation of the cup or to coact in the final stage of its formation as well as to effect the transfer of the finished article and its welding to the sheet 24.

A plurality of die-formations similar in shape to 12 or of different shapes may be provided in a row or rows or in any required array on a single die-base or block for simultaneous formation of a plurality of containers similar to the container shown in FIG. 3 in abutment with the male die portion 12 upon removal from the cavity. The die-block 17 is provided with plural cavities such as 17 each adapted to mate with a respective male die nose. The male die-portions 12 may be provided on a rectangular block or in a cylindrical array as described hereafter. If the nose portion(s) 12 are rectangular in cross-section rather than tapered as shown, the formed open container 20 will remain thereon due to friction upon removal of 12 from cavity 18 without the need for applying a suction pressure between the die and the cup.

The notation 12' refers to a cavity in the end of the nose portion 12 of the die 10 which may be used to perform either or both of two functions. Said cavity 12 may be utilized to coact with a pressure welding tool tip 26 protruding from base as hereafter described. It may also be shaped with outwardly tapering side-walls in a manner whereby the cup formation 20 will be held against 12 when the latter is removed from the cavity 18 in 17. The shape of 12' may be such that it will so maintain 29 against 12 when the dies separate, yet will permit the removal of 20 therefrom after the base 22 of 20 is welded or adhered to the base sheet as illustrated in FIG. 5. The cavity 12' in 12 may thus serve the dual functions of coacting in effecting the pressure welding of the base 22 of 20 to a second member and maintaining said container on the die until said weld is effected for transportation over said second member.

The male die 10 is also provided with means for trimming the resulting cup shaped container 20 from the surrounding sheet so that all that remains is a bowl with a circular rim as illustrated in FIG. 3. Said trimming may be effected by means of a circular cutting die or knife 13 which is held in an angular cavity surrounding the die nose 12 by means of a ring 14 which die projects beyond the surface of that part of 10 which surrounds the nose which is referred to by the notation 11. The notation 15 refers to an annular washer of rubber which is bonded to the face of 14 and normally projects beyond the face 11 which serves to separate the scrap material 19" from the material of the cup 20 when the die is lifted as in FIG. 3. The notation 16 refers to a hole through the nose 12 and base 11 of the die 10 which extends to the face of the nose from a control valve (not shown) which valve is connected to both fluid suction and pressure means. Suction pressure applied on the line 16 will hold the cup formation 20 against the male die 10 as illustrated in FIG. 3 so that it will be removed thereby from the cavity and can be transported through a fastening or welding station such as illustrated in FIG. 4.

In my said copending patent application, the packaging structure illustrated in FIG. 5 is provided which may comprise a plurality of cup shaped containers 20 each of which has a corrugated side wall 21 and flat bottom 22 with the bottom of each container secured to a base sheet 24 by welding or bonding by means of an adhesive or fusion of one or heated thermoplastic materials. The term bond where used hereafter shall therefore refer to securing of the container to the base or retaining sheet by means of an adhesive or by welding means. The base sheet 24 may comprise a wall of a master container against which a number of the smaller containers 20 are held by welding or other means and are each adapted to retain a material or other product therein. If the material contained by the cup shaped containers 20 is a candy or single portion of food such as a cupcake, it will quite often be desired to remove the unit container 20 with the product remaining therein in order to retain said product until it is eaten or otherwise dispensed of. The bottom 22 of each container is therefore removably secured to the base sheet 24 by means of an adhesive placed between the two or a spot weld, such as 23, having a characteristic such that the container 20 may be removed from 24 by hand without difficulty by means of a simple pulling action in which the weld 23 is broken or torn. The same male die 10 which formed the container may be utilized to effect said welding after the cup is formed without removal of said cup from the nose 12 of the forming die.

When the die 10 retracts, the spot weld 23 between the bottom 22 and sheet 24 will retain the cup 20 against 24 and separate the nose 12 of the die from said container 20. For certain applications it may be desirable to apply a positive pressure to the duct 16 to facilitate removal of the die nose 12 from the corrugated cup 20.

A fast setting adhesive may also be applied as a spot to either or both the abutting faces of 22 or 24 which adhesive will removably retain 20 on 24 when it hardens. If a non-drying pressure sensitive adhesive is utilized, then it will be required to apply a positive pressure to the line 16 in order to separate container 20 from the nose 12 before the die is lifted therefrom, to repeat the cycle of operations.

FIG. 6 shows a modified die design for effecting a resistance or ultrasonic welding of the materials of the cup 20 and a base sheet referred to by the notation 35. It is assumed that the male die 30 has been used to form the cup shaped foil container by the method of FIGS. 1 to 3 and said die has thereafter advanced said held container by mechanical or suction means against the upper face of 35 which is shown abutted against a flat surface of the die block 36. A bore is provided through the male die base 31 and the nose portion 32 thereof. Inserted in said bore is an insulating sleeve 33 of any suitable material which holds an electrode 34 therein having a tip 34 which projects slightly beyond the end of the nose 32 or is movably projectable therethrough in a manner whereby it may be used to compressively engage the upper surface of the bottom of the container 20. Electrical or ultrasonic energy applied between the electrode and the platen 36 which is grounded at 36', if generated at the correct frequency and intensity while the tip 34' of the transducer 34 compressively engages the bottom wall of 20 against 35, may be utilized to effect a spot weld 23 between the materials of 22 and 35. The retaining action of the weld and/or pressure applied through a bore such as 16 may be utilized to separate the die from the cup when die 10 lifts away from 25.

Resistance of magnetostrictive welding means may also be utilized to effect a spot weld between the sub-container 20 and the base sheet 24 whereupon notations 34 would refer to a resistance or magnetostrictive Welding electrode. If the materials of either 20 or 24 are thermoplastic materials, or are coated or laminated with thermo-plastics the electrode 34 may be a resistance heating element or rod which protrudes from the end of die nose 12 adapted to apply sufiicient heat to the bottom 22 of 20 to melt sald thermo-plastic material in the immediate vicinity of the electrode for effecting said spot welding.

The duct 16 may also be used for the passage of a liquid or other fluent material therethrough for partially filling the container 20 after it has been secured to the base sheet 24. The liquid may be any flowable liquid which is gated through a valve which is controlled to operate either while the die is in the act of retraction from the sheet 24 after the weld is effected, or when It) has completely withdrawn from the interior of the container 20. The fluid or liquid passed through 16 to be contained by the corrugated container 20, may also be used as a means for supplementing the action of separating the sheet container from the nose 12 of the die. The single duct 16 may be used to perform two or more of the multiple functions described by the use of a multiple position valve in the line 16 or tubing connected thereto which communicates with a source of pressure, vacuum or pressurized liquid. A plurality of ducts 16 extending through the nose 12 of 10 may also be utilized for faster filling the container or for performing different of the mentioned operations.

In FIG. 1 the notation 17' refers to a duct or passageway provided through' the female die 17 and terminating at the bottom wall of the cavity 18. Positive and/0r vacuum pressure may be applied to the duct 17 for either aiding in the ejection of the container 20 or assisting in the formation of said container during the initial phase of the movement of 12 in 18. If the material 19 is a thermoplastic which has been heated to a semi-molten condition, the die 17 may be utilized as a vacuum forming mold by the application of a negative pressure to the line 17 after the sheet 19 is heated, to draw said material into the cavity 18 prior to or as the nose portion 12 descends therein. The formation of 20 may thus be completed or partially completed by the time 12 advances into the cavity.

Another welding arrangement is illustrated in FIG. 7. The cup 20 is shown formed on the nose of a male die 10 and is shown in abutment with a sheet of material 35. The sheet is shown laminated to a sheet of greater thickness, the assembly being referred by the notation 39. The notation 35 refers to an adhesive between 35 and 39 provided for holding the two together as a lamination or sandwich construction. The material 40 may be cardboard or plastic and a hole 40H is provided therethrough so that an electrode 34", which is mounted in a tubular insulator 33', will reach the bottom surface of the sheet 35. The electrode 34", which is secured to the press platen or die bed 38, has its tip projecting sufficiently above the upper face of 38 or is projectable therefrom so that it will compress the sheet 35 against the bottom face of 20. When electrical or ultrasonic energy is applied by means of 34" to the face of 35 it will effect a weld between 35 and 20 and the assembly may be lifted off 33 to clear the end of the electrode 34 or the latter retracted after welding.

It is noted that the laminated assembly or sheet 39 may be used for the base sheet of the configurations of FIGS. 4 and 6 if openings tfiH are provided in the sheet 49 to permit each die or welding tool to pass to the metal portion of the combination. If the material comprising 2t) is a thermoplastic material or is coated with a thermoplastic material, then the electrodes 34 and 34" preferably contain the necessary heating elements to effect a spot weld between two surfaces which are in abutment with each other.

The welding apparatus illustrated in FIGS. 1 to 7 may be applied in an integrated assembly and filling machine for the automatic assembly and filling of such products as boxed candies, baked goods such as cupcakes and the like, various types of foods such as individual portions of fresh fruits, cooked or semi-cooked foods such as vegetables, desserts, ice cream or the like. In FIG. 8 the basic components of an automatic package forming and filling machine are illustrated which utilizes part of the eventual package as a means for conveying a plurality of small containers past filling apparatus and into a shipping or master carton. In FIG. 8 a plurality of the heretofore described foil or sheet containers are simultaneously formed and positioned against and welded to a base sheet which is continuously fed from a roll, said base sheet acting as a conveyer for thereafter moving and prepositioning said containers relative to product filling apparatus. The base sheet with the filled or partially filled product contained in the containers welded thereon may then be passed through further processing apparatus such as a heating Zone or oven, whereafter it may be further processed by cutting into a predetermined length and/or shaping it into at least part of a container. In FIG. 8 the predetermined lengths of the base sheet are automatically loaded into open boxes as they are cut, such operation eliminating substantially all of the manual operations presently required for a similar type of packaging operation.

FIG. 8 illustrates automatic machinery for forming and filling packaging of the type heretofore described and utilizes for components thereof, apparatus of the type illustrated in FIGS. 1 to 7. A sheet 51 of a first material such as metal foil, plastic or a laminate is intermittently fed from a first supply roll 50 into a forming press which is illustrated as comprising a bed 54, against which a portion of the sheet 51 is compressed and deformed into cavities therein by means of a dieblock or male mold base 55 which mounts one or more of the aforedescribed male die portions. The bed 55 is adapted to be moved up and down on tracks or guides 55' extending from an upper bed or carriage 56 which is adapted to be moved longitudinally on tracks 57 which are supported from above. Respective servo means or fluid cylinders (not shown) are interlocked in their operation and automatically controlled to retract and advance the lower die assembly or portion 55 to form the cup shaped containers from sheet 51 and to transport the container formations on the male die-portions over a bucking member or bed 61 of a fastening or welding press. A plurality of powered rollers such as 52 and 53 are automatically controlled in their operation to feed and preposition lengths of the sheet 51 from roll 50 beneath forming press 55 to hold it thereagainst, and to remove the scrap therefrom.

A second sheet of material 60 feeding from a second supply roll 59 is advanced over the press bed 61 onto which a plurality of the containers 20 are placed when the press bed 55 moves thereover and advances towards 61. The containers or cups 20 are secured in an orderly, predetermined array on 60 by one of the heretofore described techniques. The base sheet or laminate 60 is then power driven as an elongated belt by aligned pairs of power rotated drive rolls represented by the notations 62 and 63 which are mounted on bearings supported by a frame (not shown) and are power operated by means of a chain drive to move 60 at a constant speed. The movement of 66 may be continuous if the press carriage 56 is controlled in its movement to move at the same speed as 60 for a short distancewhile the bed member 55 is advanced and bonding or welding is being effected between the bases of the containers 20 held thereby and the sheet 60. The means for driving sheet 60 may also be intermittently operated and inter locked in its operation to cause a predetermined length thereof to remain stationary over 61 while one or more rows of the cups 2b are prepositioned over said length or portion thereof and are welded or bonded thereto.

The sheet 6b is adapted to be guided past an automatic machine 64 for filling or placing predetermined quantities of materials or articles in respective of the containers 20 through chutes 65 or other means extending over respective lanes of the sheet 69. The release of material(s) or objects from the machine loader 64 may be effected by means of valves or the like operated by solenoids or motors which are interlocked in their operation to the movement of the sheet 60 or are synchronized or otherwise controlled to release said material(s) at predetermined times during the cycle. The notation 66 refers to a plurality of belt conveyors which may be kept loaded by conventioned means, the movement of each of which may be controlled to automatically effect the deposition of material or objects into respective of the chutes 65 for loading into respective of the containers. Various known designs for intermittently operating filling apparatus may be employed as part of the loading machine 64.

The belt or sheet 60 continues in its movement beyond 64 whereafter the contents of the filled containers 20 may be further processed by heating, refrigerating or the addition of other materials thereto. The contents of the containers may be baked or otherwise cooked, frozen or otherwise treated.

At its end, belt 60 with the filled containers thereon passes thru a cutting machine 67 which is operative to cut 60 into predetermined lengths 60' which may individually and automatically be loaded into cartons 68 which pass in front of 67 on a belt conveyor 69. The movement of the belt 69' of conveyor 69 may be intermittent and synchronized to the operation of 60 so that one or more lengths 60 of the cup mounted base 60 will be deposited in each container.

The notation 71 refers to a machine for further operating on the container and/or product therein. For example, the container 68 may be closed or capped in 71, stacked or cartoned.

The operation of the servo-motors driving the sheets 51 and 60, those advancing and retracting 55 and 56, the servos releasing or delivering predetermined quantities of product to or from chutes 65, the shear or rotary cutting mechanism of 67 and the movement of the belt of conveyor 69 may be controlled by an automatic se quencing controller such as a self recycling multi-circuit timer or any other control means of known design which is preferably interlocked by limit and/or other switches to effect the mentioned fabrication and filling functions.

It is noted that the base sheet material 60 may be driven either continuously or intermittently past the filling machine 64 which action will depend on the material being conveyed thereby into the individual containers, its rate of flow from the spouts 65 and the lineal speed of 60. In other words, filling may be accomplished on-thefly while sheet 60 is in motion or while 60 is momentarily stopped with respective of the sub-containers 20 prepositioned relative to aligned filling chutes or spouts 65. The means for operating the roller drives 62, 63 may be a stepping motor or conventional electric motor having the desired acceleration andstopping characteristics.

FIG. 9 illustrates schematically a system for controlling the apparatus of FIG. 8 including basic servos and controls which are shown in block notation. The notations 78 and 79 refer to motor drives or gear motors for respectively effecting the drive of sheet materials 51 and 50 through respective sets of roller drives 53 and 63. A lineal motor or hydraulic cylinder 72 advances and retracts carriage 56 and a second lineal motor 75 mounted on 56 lowers and raises male die-bed 55. The control apparatus of FIG. 9 will best be described by reference to a cycle of operation. It is assumed that the proper power supplies are provided on the correct side of all switches and controls.

Assuming that die 55 is retracted with the containers retained by the die formations 12 thereof, and that servo 72 is operating to drive 56 to position 55 over bed 61 and sheet 60, when shaft 728 of cylinder 72 is fully projected a limit switch 72' having an arm riding on said shaft is actuated when said arm rides in an indentation therein. The operation of limit switch 72' effects the energization of a self-recycling multi-circuit timer 73 which effects the following actions during a cycle of its operation.

The timer 73 energizes the stop control 723 of lineal motor 72 stopping 56 over 61. The forward drive control 75F of lineal motor 75 is next energized to cause to be advanced to cause the formed parts retained by the male die portion 12 to be compressively engaged against the upper surface of base sheet 60 and welded or bonded thereto as described. If ultrasonic, resistance, or mag netic-resistance welding is to be effected, the timer 73 may operate a generator 74 of the necessary electrical energy when the die-block 55 is advanced, for the time necessary to energize the transducers 34 and effect said welding, by supplying the necessary power to the input of 74 or energizing the controller 74 of 74.

While the timer 73 may be used to control the servos for effecting the filling of the individual cups 20 further down the conveyor, the cutter in 67 and the operation of conveyor 69, another means is illustrated which employs a second multi-circuit, self-resetting, repeat-cycle timer 77. The die block 55 is provided with a notching blade 550 which provides a position indicating cut-out or edge notch in sheet 60 when it advances thereagainst, which cut-out is provided in advance of the group of containers welded to 60 in the same action. A limit switch 76 is adapted with its actuator positioned to ride in or against the cutout provided by 55c and, when actuated thereby, energizes the timer 77 which, at predetermined time intervals, during which respective containers are beneath respective of the filling spouts 611 to 65N, energizes respective solenoids 618-1, 61S-N which operate valves or gates permitting predetermined quantities of the materials conveyed to the chutes to pass through to the containers below.

The programmed controller 77 also effects the operation of the cut-off mechanism 67 by energizing a solenoid or servo 67' at the proper instant to cause a blade 67K to shear sheet 60 near its end. The blade 67K may be a rotary or lineal cutter operated by 67 After the containers held by 55 are bonded to 60, the timer 73 energizes the reverse control 75R of servo 75 causing '75 to retract die base 55 leaving the cups 20 on 60. Timer 73 then energizes the forward control 79F of motor 79 which drives sheet 60 forward until switch 76 energizes controller 77 which controls motor 79 to stop at the proper instant by energizing its stop control 798. If it is desired to intermittently move 60, while 55 is retracted and forming new containers, to effect the filling of those containers on 60 in the area of the filling spouts, timer 77 may alternately control 79 to start and stop the desired number of times between which actions the product release controls 65S1 to 65S-N may be energized by 77 in the desired sequence.

The forward drive control 79F of servo 79 is shown energized by timer 73 although, as stated, it may be controlled by 77. Timer 73 is operative to effect the energizing of the retract control 72R of 72 and, thereafter the advance and retract controls 75D and 75U of cylinder 75 to effect the formation of the sub-containers as well as the forward drive and stop controls 78F and 788 of motor 78 to position a new length of sheet 51 in the press for the next forming action prior to the advance of 55 thereagainst. The cycle then repeats as described.

Other features of the control system of FIG. 8' include the energization of one or more solenoid operated valves such as 16V by operation of the multi-circuit timer controller 73 which occurs at the proper time interval in the cycle for providing a vacuum and/or pressure on lines such as 16, 17' and 17" associated with the forming dies to effect the functions heretofore described, the energizing of controls effecting the starting and stopping of motors for controlling other conveying apparatus associated with the machinery of FIG. 8 such as motor 69" for moving the belt 69 of conveyor 69 for feeding and prepositioning cartons such as 68 in front of the cut-off mechanism 67, or one or more of the feed conveyors 66 9 shown in FIG. 8 to maintain the storage and/ or delivery chutes of 64 stocked or filled with material.

Numerous other modifications of the present invention will be appreciated by those skilled in the art and accordingly the appended claims should be construed broadly as is consistent with the appended claims and in certain instances, some features of the invention will be used Without a corresponding use of other features.

I claim:

1. Packaging apparatus comprising in combination with a forming apparatus for simultaneously shaping a first sheet material into a plurality of individual cup-shaped containers, a conveying means for feeding said first sheet material to said forming apparatus, movable transfer means for removing containers from said forming apparatus, means for prepositioning a second sheet material relative to said forming apparatus, means for moving said transfer means with the containers engaged thereby towards said second sheet material to compress the bottoms of said containers against said second sheet material, and means for bonding the bottoms of said containers to said second sheet material.

2. Packaging apparatus comprising in combination with separable male and female dies for simultaneously forming a plurality of containers from a first sheet material, a conveying means for feeding said sheet material to said dies, means for holding the formed containers on one of said dies, said one die comprising a transfer means for the containers formed thereon, means for prepositioning a second sheet material, means for moving said one die to compressively engage said formed containers against said second sheet material, means to bond a portion of the wall of each container to said second sheet material, means for disengaging said containers from said one die and for removing said die from said second sheet material, and means for recycling said one die whereby it engages a new section of said first sheet material and cooperates with the other die in forming a new plurality of containers.

3. Apparatus in accordance with claim 2, in which said one die member comprises a welding tool operative to weld part of the wall of said container to said second sheet material.

4. Packaging apparatus comprising in combination with a forming apparatus comprising first and second die means for simultaneously shaping a first sheet material into a plurality of containers, a conveying means for feeding said sheet material to said forming apparatus, means for holding the formed containers on said first die means, means for prepositioning a second sheet material, means for moving said first die means to compressively engage said containers against said second sheet material, means for bonding a portion of the wall of each container to said second sheet material, means for disengaging said containers from said first die means and for moving said die means from said second sheet material, and means for recycling said first die means to cooperate with said second die means in forming a new plurality of containers.

5. Packaging apparatus comprising in combination with a pair of cooperating die means for simultaneously shaping a first sheet material into a plurality of cup-like containers, means for feeding said sheet material to said pair of die means, a bucking means prepositioned relative to said pair of die means, means for guiding and moving a second sheet material across said bucking means, means for moving one of said die means with the formed containers engaged thereon towards said bucking means whereby to compressively engage each container against said second sheet material, and means for effecting a bonding of said containers to said second sheet material whereby when said movable die means is removed therefrom the containers will remain in bonded assembly with said second sheet material.

6. Packaging apparatus comprising in combination with a pair of cooperating die means for simultaneously shaping a first sheet material into a plurality of cup-like containers, means for feeding said sheet material to said pair of die means, a bucking means prepositioned relative to said pair of die means, means for guiding and moving a second sheet material across said bucking means, means for moving one of said die means with the formed containers engaged thereon towards said bucking means whereby to compressively engage each container against said second material, each of said movable die means having a welding die portion which is adapted to weld a small area of the wall of each container to the material of said second sheet material.

7. Packaging apparatus comprising in combination with a pair of cooperating die means for simultaneously shaping a first sheet material into a plurality of cup-like containers, means for feeding said sheet material to said pair of die means, a bucking means prepositioned relative to said pair of die means, means for guiding and moving a second sheet material across said bucking means, means for moving one of said die means with the formed containers engaged thereon towards said bucking means whereby to compressively engage each container against said second material, said movable die means having a Welding die portion which is adapted to Weld a small area of the wall of each container to the said second sheet material, and means for moving said second sheet material to position a new section thereof in alignment with said bucking means for welding containers thereto.

8. An automatic packaging apparatus comprising in combination a feeding means for simultaneously feeding a plurality of preformed individual containers which includes means for simultaneously prepositioning the bottoms of each of said containers against a base made of sheet material, a bonding means for securing at least part of the area of the bottom of each container to said sheet material with said containers aligned in a plurality of parallel rows thereon in a manner such that as the sheet is conveyed the containers will be retained in fixed relation to said base sheet, means for moving said sheet material in a direction parallel to the rows of said containers, an automatic filling apparatus, a conveying means for guiding said base sheet in its movement past said automatic filling apparatus, said automatic filling apparatus comprising a plurality of product dispensers, at least one dispenser being positioned adjacent each of said rows of containers for discharging a product therefrom into containers as said containers become aligned therewith, and means for controlling each dispenser to transfer its product to respective of said containers in synchronization with the movement of said base sheet.

9. Packaging apparatus in accordance with claim 8, including means for conveying said base sheet beyond said automatic filling apparatus, a second conveyor for conveying a plurality of cartons, means for operating said second conveyor to position a carton in alignment with the conveying means for said base sheet and means for transferring lengths of said base sheet containing predetermined numbers of said filled containers to said cartons.

10. Apparatus in accordance with claim 8 including a cutting means for said base sheet material, said cutting means being synchronized in its operation to the movement of said sheet material and adapted to sever sections from the end of said sheet with each of said sections having said containers retained in substantially the same relative positions thereon as containers retained on the other sheet sections severed by said cutting means.

l1. In an apparatus for continuously filling a plurality of unit containers moving on a conveyor belt which is guided and moved beneath a plurality of discharge means located above said conveyor belt for discharging predetermined quantities of material into said containers, the improvement which comprises means for prepositioning said containers in a longitudinal array of parallel rows on said conveyor belt, means for bonding each container 1 1 against said belt, means for synchronizing the operation of each discharge means with the movement of said conveyor belt whereby a predetermined material is dispensed therefrom when a container is directly beneath said discharge means, and means for severing predetermined lengths of said belt.

12. Packaging apparatus comprising in combination with a pair of cooperating die means for simultaneously shaping a first weldable sheet material into a plurality of cup-like containers, means for feeding said sheet material to said pair of die means, a bucking means positioned relative to said pair of die means, means for guiding and moving a second weldable sheet material across said bucking means, means for moving one of said die means with the formed containers engaged thereon towards said 15 2888862 therefrom the containers will remain in welded assembly with said second sheet material.

References Cited in the file of this patent UNITED STATES PATENTS 2,363,417 Heywood Nov. 21, 1944 2,378,324 Ray et al. June 12, 1945 2,833,095 Stuart May 6, 1958 2,886,927 Fisk May 19, 1959 Williams June 2, 1959 

